Precast concrete module which can be adapted internally to multiple uses

ABSTRACT

These modules can also be grouped as necessary for additional space, or other purposes. Each module consists of a horizontal slab, vertical walls along the perimeter of the slab, interior walls positioned according to individual spatial configuration, and a pre-stressed roof. Roof is a separate, pre-stressed element in which will be welded and bolted to the perimeter walls of the module. The roof is provided with holes for screws used for attachment, and PVC pipes for ventilation purposes. Walls consist of openings for light, and both air and human circulation.

FIELD OF INVENTION

This invention relates to prefabricated concrete modules that can be adapted internally to multiple programs or uses. Also, it relates to pre-stressed concrete slabs being used for module's roof.

BACKGROUND

Prefabricated concrete structures offer an alternative to conventional construction. Benefits from prefabricated concrete structures include flexibility, reliability, and reduction of construction period. Quality of the final object rises due to structures being produced in a controlled environment. Also, this type of construction is environmentally friendly due to reduction of waste materials. These structures, once produced, can be transported easily and assembled with minimum labor.

Prior, prefabricated concrete units were formed by the assembly of individual components such as floor, walls, and roof. This type of assembly creates joints between elements that may cause filtration and cracking in a near future. Later, U.S. Pat. No. 4,606,878 demonstrates a prefabricated unit in which the floor, three walls, and roof were casted as an integral unit. The fourth wall was left open in order to remove the interior mold. U.S. Pat. No. 5,893,241 demonstrated a concrete unit in which the floor and perimeter walls are casted as an integral unit. The roof is a separate component that is inserted to the rest of the unit.

However, most prefabricated units are empty internally. Partitions inserted in units suffered damage in joint areas caused by transportation vibrations and other forces. Our modules comprises of a floor, perimeter walls, and interior walls casted as an integral unit. Later, a pre-stressed concrete roof is inserted to complete the unit. Allowing the interior walls to be casted to the module, instead of inserting them, improves resistance to vibrations while minimizing joints to be caulked or sealed. These modules can then have multiple spatial configurations. This breaks the idea of creating a module for each use.

DESCRIPTION

FIG. 1: Exploded isometric view of precast concrete module

FIG. 2: Elevation view of structural wall

FIG. 3: Multi-view of lifting plate

FIG. 4: Isometric view of pre-stressed roof

FIG. 5: Elevation view of interior wall welded in place

FIG. 6: Detail of module connection to foundation system

FIG. 7: Detail of two modules connection to foundation system

FIG. 8: Detail of two modules connection at roof

Legend 1 Horizontal slab (floor) 2 Structural perimeter wall 3 Non-structural perimeter wall 4 Interior wall 5 Interior wall (welded in place) 6 Pre-stressed roof 7 Openings 8 Screws 9 Hooks 10 Welding plate 11 Lift plate 12 Foundation Pier 13 Cable 14 Hole for Vent Pipe 15 Hole for Screw 16 Hole for screw in lifting plate 17 Hole for crane's hook in lifting plate 18 Flashing

To avoid confusion, numbers shown in the illustrations are referenced in the legend above.

To begin module construction, the floor (1) is casted after inserting welding plates (10) that will be used to connect said floor to both foundation piers (12), and interior walls (5) that are welded in place. The position of the welding plates depends on the spatial configuration and foundation layout. Following the structural walls (2) are then casted with welding plates inserted for roof connection and possible interior wall welding. Welding plates for roof (6) are positioned at 1 foot from each end of the wall (2) and center of each wall (2). Non-structural walls (3) and interior walls (4) are then casted following the same procedure of the structural walls (2).

Interior walls welded in place (5) are inserted as shown in FIG. 5. Each wall (5) contains a welding plate (10) positioned at the bottom for floor (1) connection, top for roof (6) connection, and at the side for adjacent wall connection. The side welding plates are positioned at 2 feet from the lower and upper edge. At the top is a hook (9) inserted to allow for the movement of said wall into place. Once the wall is welded in place, gap left for hook (9) is filled with mortar or other bonding agents. Containing walls that are welded in place allows for different space configurations and for non-conventional partitions.

Then the pre-stressed concrete roof is bolted and welded to the rest of the unit as shown in FIG. 2. The roof (6) is provided with holes (15) for screws (8) to pass through to allow for fastening to vertical walls (2). The roof (6) also contains holes (14) for vent pipes if necessary. The position of the screws (8) is fixed at five feet from each end of wall (2). However, the vent pipes' position depends on the interior configuration and module use. Vent pipes are to extend 1 foot from top surface of roof (6) to comply with existing building codes. Hooks (9) are positioned three feet from each end of roof side surface (6) and at each center of said roof side. These hooks (9) are used only for installing roof (6) to the unit. Once installed, the hooks (9) are removed. Lifting plate (11) is used for both roof fastening and module lifting. These plates (11) are located at each screw (8) position. As illustrated in FIG. 3, each plate (11) contains 2 horizontal oriented holes (16) for screw (8) pass-through, and a vertical oriented hole (17) for module lifting.

The roof (6) consists of the conventional reinforcing steel grid system, and 5½″ DIA. cables (13) parallel to walls (2). These cables (13), as shown in FIG. 4, are pre-stressed to 270 KIPS (1/2) special before concrete pour. The addition of the cables (13) improves the tensile strength of the concrete roof (6), thus preventing cracks and filtration caused by module transportation and other source of damages. Once concrete pour for roof (6) is ready for installation, each cable (13) is then trimmed as close to roof as possible. Remaining cables extending from roof edge is then covered with plaster, or other means, depending on finishing materials.

During roof (6) installation, a bonding agent, such as mortar, is applied to upper edge of walls (2), (3), (4), and (5) in order to fill gaps between mentioned roof and walls. Once fastened, excess bonding agent is removed. Once roof (6), as described above, is installed, the module is ready for desirable aesthetic appearance.

Once the module is finished, it is transported to final destination. Upon arrival to site, it will be welded to corresponding foundation piers (12) as shown in FIG. 6. For welding, plates (10) must be positioned in exact location on the upper surface of each pier (12) and lower surface of the unit's floor (1). FIG. 7 illustrates the connection needed when one pier (10) is to be shared by two to four modules. When two modules are placed adjacent to each other, flashing (18) is required to prevent filtration. This flashing is shown in FIG. 8. For drainage issues, roof (6) is sloped slightly towards the middle, in which water will reach to a pipe that will release the water from the roof. This pipe can be extended towards a cistern or tank for water capturing or recycling. 

What is being claimed:
 1. A precast concrete module consisting: a) Horizontal slab in which perimeter walls, and interior walls are casted as an integral unit. b) Pre-stressed concrete roof, casted separately form the unit.
 2. Concrete module, as in claim 1, comprises of a horizontal slab which contains welding plates for the attachment to foundation piers to allow for topographical flexibility, and to interior walls shorter than 3 feet in length.
 3. Concrete module, as in claim 1 or 2, comprises of vertical walls along perimeter in which two opposite structural walls contain screws extending beyond upper edge for roof attachment and module lifting support.
 4. Concrete module, as in claim 1, 2 or 3, comprises of vertical walls along perimeter which contain welding plates at each end, and center of the upper exterior edge of said walls for roof attachment.
 5. Concrete module, as in claim 1, 2, 3 or 4, comprises of vertical walls with different sized openings for light, airflow, and human movement.
 6. Concrete module, as in claim 1, 2, 3, 4 or 5, comprises of interior walls shorter than 3 feet in length which contain welding plates at the bottom for floor connection, at the side for adjacent wall connection, and at the top for roof connection.
 7. Concrete module, as in claim 1, 2, 3, 4, 5 or 6, comprises of a pre-stressed concrete roof that will be welded and bolted to the top of perimeter walls and interior walls welded in place.
 8. Concrete module, as in claim 7, comprises of a pre-stressed roof that contains holes for ventilation pipes, when necessary, and screws for attachment to walls and lifting plates.
 9. Concrete module, as in claim 8, comprises of a pre-stressed roof that contains hooks for module erection.
 10. Concrete module, as in claim 9, comprises of a pre-stressed roof in which the top surface is sloped relatively to under-surface for water drainage assistance. 